SECTION 4A

HYDRAULIC BRAKES
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise
noted.

TABLE OF CONTENTS
Description and Operation . . . . . . . . . . . . . . . . . .
Warning Lamp Operation . . . . . . . . . . . . . . . . . . .
Component Locator . . . . . . . . . . . . . . . . . . . . . . . .
Brake System (Non-ABS) . . . . . . . . . . . . . . . . . .

4A-2
4A-2
4A-3
4A-3

Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Hose (Front) . . . . . . . . . . . . . . . . . . . . . . . .
Brake Hose (Rear) . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Information and Procedures . . . . .

Brake System Testing . . . . . . . . . . . . . . . . . . . . . .
Brake Hose Inspection . . . . . . . . . . . . . . . . . . . . .
Warning Lamp Operation . . . . . . . . . . . . . . . . . . .

4A-4
4A-4
4A-4
4A-5

Stoplamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9

Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13
General Specifications . . . . . . . . . . . . . . . . . . . . 4A-13

Brake System Fault . . . . . . . . . . . . . . . . . . . . . . . . 4A-5

Manual Bleeding the Brakes . . . . . . . . . . . . . . . . 4A-6
Pedal Travel Check . . . . . . . . . . . . . . . . . . . . . . . . 4A-6

Fastener Tightening Specifications . . . . . . . . . . 4A-13

Schematic and Routing Diagrams . . . . . . . . . . 4A-14
Brake Lamp Warning Circuit . . . . . . . . . . . . . . . 4A-14

Brake Pedal Free Play Inspection . . . . . . . . . . . 4A-7

Stoplamp Switch Circuit . . . . . . . . . . . . . . . . . . . 4A-14

DAEWOO M-150 BL2

4A-8
4A-8
4A-8
4A-9

4A 2 HYDRAULIC BRAKES

DESCRIPTION AND OPERATION

WARNING LAMP OPERATION
This brake system uses a BRAKE warning lamp located
in the instrument panel cluster. When the ignition switch
is in the III position, the BRAKE warning lamp should illuminate. It should go off when the ignition switch return
to II position. The following conditions will activate the
BRAKE warning lamp.
D The lamp should be on whenever the parking brake
applied and the ignition switch is in the II position.
D A low fluid level in the master cylinder will turn the
BRAKE warning lamp on.

D17A007A

DAEWOO M-150 BL2

HYDRAULIC BRAKES 4A 3

COMPONENT LOCATOR
BRAKE SYSTEM (NONABS)
(LeftHand Drive Shown, RightHand Drive Similar)

MAB4A001

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Power Booster
Power Booster Boot
Cotter Pin
Clevis
Clevis Pin
Packing
Spacer
Master Cylinder Assembly
Fluid Reservoir Assembly
Reservoir Cap
Reservoir
Grommet Seal
Master Cylinder
Proportioning Valve
Stoplamp Switch
Brake Pedal Assembly
Clutch Pedal Spring

DAEWOO M-150 BL2

18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

Pedal Bracket Assembly

Clutch Pedal Pad
Clutch Pedal
Cushion
Bushing
Retaining Ring
Spring
Brake Pedal Pad
Brake Pedal
Brake Pedal Spring
Accelator Pedal Pad
Accelator Pedal
Rear Drum Brake Hose
E Ring
Front Disc Brake Hose
Brake Hose Coupling Bolt
Plain Washer

4A 4 HYDRAULIC BRAKES

DIAGNOSITIC INFORMATION AND PROCEDURES

BRAKE SYSTEM TESTING
(LeftHand Drive Shown, RightHand
Drive Similar)
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake performance cannot be made if the roadway is wet, greasy, or
covered with loose dirt whereby all tires do not grip the
road equally. Testing will also be adversely affected if the
roadway is crowned so as to throw the weight so roughly
that the wheels tend to bounce.
Test the brakes at different vehicle speeds with both light
and heavy pedal pressure; however, avoid locking the
brakes and sliding the tires. Locked brakes and sliding
tires do not indicate brake efficiency since heavily
braked, but turning, wheels will stop the vehicle in less
distance than locked brakes. More tire-to-road friction is
present with a heavily braked, turning tire than with a
sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:
D Tires having unequal contact and grip of the road will
cause unequal braking. Tires must be equally inflated, and the tread pattern of the right and the left
tires must be approximately equal.
D Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.
D Misalignment of the wheels, particularly conditions of
excessive camber and caster, will cause the brakes
to pull to one side.
To check for brake fluid leaks, hold constant foot pressure on the pedal with the engine running at idle and the
shift lever in NEUTRAL. If the pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking. Perform a visual check to confirm any suspected leaks.
Check the master cylinder fluid level. While a slight drop
in the reservoir level results from normal lining wear, an
abnormally low level indicates a leak in the system. The
hydraulic system may be leaking either internally or externally. Refer to the procedure below to check the master cylinder. Also, the system may appear to pass this
test while still having a slight leak. If the fluid level is normal, check the vacuum booster pushrod length. If an incorrect pushrod length is found, adjust or replace the
rod.

Check the master cylinder using the following procedure:

D Check for a cracked master cylinder casting or brake
fluid leaking around the master cylinder. Leaks are indicated only if there is at least one drop of fluid. A
damp condition is not abnormal.
D Check for a binding pedal linkage and for an incorrect
pushrod length. If both of these parts are in satisfactory condition, disassemble the master cylinder and
check for an elongated or swollen primary cylinder or
piston seals. If swollen seals are found, substandard
or contaminated brake fluid should be suspected. If
contaminated brake fluid is found, all the components
should be disassembled and cleaned, and all the rubber components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, then the rubber parts
have deteriorated. This deterioration may also be evidenced by swollen wheel cylinder piston seals on the
drum brake wheels.
If rubber deterioration is evident, disassemble all the hydraulic parts and wash the parts with alcohol. Dry these
parts with compressed air before reassembly to keep alcohol out of the system. Replace all the rubber parts in
the system, including the hoses. Also, when working on
the brake mechanisms, check for fluid on the linings. If
excessive fluid is found, replace the linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush the
master cylinder with brake fluid, refill the master cylinder, and bleed the system. Refer to Manual Bleeding
the Brakes in this section.

BRAKE HOSE INSPECTION

The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of the
outer cover, and for leaks or blisters. Inspect the hoses
for proper routing and mounting. A brake hose that rubs
on a suspension component will wear and eventually
fail. A light and a mirror may be needed for an adequate
inspection. If any of the above conditions are observed
on the brake hose, adjust or replace the hose as necessary.

DAEWOO M-150 BL2

HYDRAULIC BRAKES 4A 5

WARNING LAMP OPERATION

This brake system uses a BRAKE warning lamp located
in the instrument panel cluster. When the ignition switch
is in the III position, the BRAKE warning lamp should
glow and then go OFF when the ignition switch returns
to the II position.

The following conditions will activate the BRAKE lamp:

D Parking brake applied. The light should be on whenever the parking brake is applied and the ignition
switch is II.
D Low fluid level. A low fluid level in the master cylinder
will turn the BRAKE lamp ON.

BRAKE SYSTEM FAULT

Condition

Brake Warning Lamp ON

Stoplamp ON

Poor Braking

Dragging Brake

Pedal Over Stroke

DAEWOO M-150 BL2

Probable cause

Correction

D Brake fluid leaks.

D Repair the leaks or add th fluid.

D Parking brake switch shorted to

ground.

D Repair the short ground.

D Faulty the fluid level sensor.

D Replace the sensor.

D Faulty the stoplamp switch.

D Replace the stoplamp switch.

D Push rod length is short.

D Adjust the push rod length of the

power booster.

D Stoplamp switch circuit shorted to

battery.

D Repair or Replace the wiring harness.

D Brake fluid lacks or leaks.

D Repair the leaks or add the fluid.

D Brake fluid contamination.

D Replace the fluid.

D Air in the brake system.

D Bleed the brake system.

D Damaged brake lines.

D Replace the brake lines.

D Damaged vacuum hose or faulty

check valve.

D Replace the vacuum hose or check

value.

D No free play at the brake pedal.

D Adjust the free play.

D Weakened the brake pedal return

spring.

D Replace the return spring.

D Faulty master cylinder.

D Replace the master cylinder.

D Air in the brake system.

D Bleed the brake system.

D Brake fluid lacks or leaks.

D Repair the leaks or add the fluid.

D Poor adjustment of the brake pedal

free play.

D Adjust the push rod length of the

power booster.

4A 6 HYDRAULIC BRAKES

MANUAL BLEEDING THE BRAKES

Important: The bleeding sequence is as follows; right
rear, left rear, right front, and left front.
Important: Check the fluid level and add the fluid during
the bleeding operation.
1. Raise the vehicle.
2. Remove the bleeder screw and cap.

5. Tighten the bleeder screw after loosening the bleeder

screw and draining the fluid.
Caution: Hold the brake pedal until tightening the
bleeder screw.
6. Repeat the step 5, 6 until all the air is removed.
7. Check the leaks for the bleeder screw.

PEDAL TRAVEL CHECK

1. Start the engine.
2. Push the pedal three times.
3. With brake pedal depressed with a about 30Kg (66.15
lb) load, measure the clearance between the pedal
pad and the lower dash panel.
Unit : mm (in.)

Specification

60 (2.36)

D17B703B

3. Attach a transparent tube over the valve. Allow the

tube to hang submerged in brake fluid in a transparent container.

D107A304

4. If clearance is less than 60mm (2.36 in.), the most

possible cause is either rear drum brake shoes are
worn out beyond the specification value or air is in
lines. Clearance still remains less than 60mm (2.36
in.) even after replacement of brake shoes and bleeding of the brake system, other possible but infrequent
cause is malfunction of rear drum brake shoe adjusters or booster push rod length out of adjustment.
5. Automatic clearance adjuster check is performed after removing brake drums. If the faulty is found, repair
or replace it.
D107A303

4. Slowly push the brake pedal several times and hold

the brake pedal.

DAEWOO M-150 BL2

HYDRAULIC BRAKES 4A 7
3. Brake pedal free play can not be adjusted.

BRAKE PEDAL FREE PLAY

INSPECTION
1. Push the brake pedal several times to discharge the
vacuum of the power booster.
2. Measure the pedal movement until the hardness is
felt when pushing the brake pedal by hand.

Unit : mm (in.)

Specification

610 (0.240.31)

D107A305

DAEWOO M-150 BL2

4A 8 HYDRAULIC BRAKES

REPAIR INSTRUCTIONS
ONVEHICLE SERVICE
BRAKE HOSE (FRONT)
Removal Procedure

D107A528

1. Remove the wheels. Refer to Section 2E, Tires and

Wheels.
2. Remove the brake hose.
D Remove the fitting (1).
D Remove the Ering retainer (2).
D Disconnect the brake hose mounting from the strut
(3).
D Remove the coupling bolt (4).
D Plug the opening in the brake pipe and caliper to
prevent fluid loss or contamination.

Installation Procedure
1. Connect the brake lines to the brake hose (1).

Tighten
Tighten the brake pipetohose fitting to 16 NSm (12
lb-ft).
2. Install the brake hose coupling bolt (2).

Tighten
Tighten the bolt to 25.5 NSm (19.1 lb-ft).
Important: Use only Daewoo recommended brake
fluid.
D17A529B

3. Bleed the brake system. Refer to Manual Bleeding

the Brakes in this section.
4. Check the brake system for leaks.
5. Install the wheels. Refer to Section 2E, Tires and
Wheels.

DAEWOO M-150 BL2

HYDRAULIC BRAKES 4A 9

BRAKE HOSE (REAR)

Removal Procedure
1. Remove the wheels. Refer to Section 2E, Tires and
Wheels.
2. Remove the brake hose.
D Remove the fittings (1).
D Remove the Erings (2).
D Plug the opening in the brake pipe to prevent fluid
loss or contamination.

D107A530

Installation Procedure
1. Connect the brake lines to the brake hose.
2. Install the fitting and Erings.

Tighten
Tighten the fitting to 16 NSm (12 lb-ft).
Important: Use only Daewoo recommended brake fluid.

D17A531A

3. Bleed the brake system. Refer to Manual Bleeding

the Brakes in this section.
4. Check the brake system for leaks.
5. Install the wheels. Refer to Section 2E, Tires and
Wheels.

STOPLAMP SWITCH
(LeftHand Drive Shown, RightHand
Drive Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the stoplamp switch.
D Disconnect the connector (1).
D Turn the stoplamp switch (2).

D107A523

Installation Procedure
1. Install the stoplamp switch.
2. Connect the electrical connector.
3. Connect the negative battery cable.
Important: After installing the stoplamp switch, pull the
lever completely.

D107A524

DAEWOO M-150 BL2

4A 10 HYDRAULIC BRAKES

BRAKE PEDAL
(LEFTHAND DRIVE)
Removal Procedure
1. Remove the stoplamp switch. Refer to Stoplamp
Switch in this section.
2. Disconnect the brake pedal from the power booster.
Refer to Section 4C, Power Booster.
3. Remove the brake pedal.
D Remove the bolt (1).

D107A525

D
D
D
D

Remove the brake pedal spring (2).

Remove the bushing (3).
Remove the cushion (4).
Remove the brake pedal pad (5).

D107A526

Installation Procedure
1. Install the pad to the brake pedal.
2. Install the brake pedal with spring, bushing, and cushion.
3. Connect the brake pedal to the power booster.

Tighten
Tighten the brake pedaltopedal bracket bolt to 18
NSm (13 lb-ft).
4. Install the stoplamp switch. Refer to Stoplamp
Switch in this section.
D17A527A

BRAKE PEDAL
(RIGHTHAND DRIVE)
Removal Procedure
1. Remove the instrument panel assembly. Refer to
Section 9E, Instrument/Driver Information.
2. Disconnect the brake pedal rod from the power
booster. Refer to Section 4C, Power Booster.

D24C001A

DAEWOO M-150 BL2

HYDRAULIC BRAKES 4A 11
3. Remove the stoplamp switch.
D Remove the stoplamp switch (1).
D Remove the bolts (2).
D Remove the stoplamp switch bracket (3).

D24D001

4. Remove the bolts mounting brake pedal bracket (1).

5. Remove the nuts mounting brake pedal bracket (2).

D24D002

6. Remove the canister. Refer to Section 1F, Engine

Controls.
7. Remove the bolt mounting brake pedal bracket in the
engine compartment (1).

D24D003

8. Remove the brake pedal.

D Remove the snap rings (1).
D Remove the bushings (2).
D Remove the brake pedal spring (3).
D Remove the cushion (4).
D Remove the brake pedal pad (5).

D24D004

DAEWOO M-150 BL2

4A 12 HYDRAULIC BRAKES
Installation Procedure
1. Install the brake pedal with pad, spring, bushings, and
cushion.
2. Install the bolt mounting brake pedal bracket in the
engine compartment.

Tighten
Tighten the bolt to 1826 NSm (1320 lb-ft).
3. Install the canister. Refer to Section 1F, Engine Controls.

D24D005

4. Install the brake pedal with the snap rings.

5. Install the bolts and nuts mounting brake pedal bracket.

Tighten
D Tighten the bolts mounting brake pedal bracket to
1826 NSm (1320 lb-ft).
D Tighten the nuts mounting brake pedal bracket to
1826 NSm (1320 lb-ft).

D24D006

6. Install the stoplamp switch with the bracket and the

bolts.

Tighten
Tighten the mounting bolts to 912 NSm (80106 lbin.)
7. Connect the brake pedal rod to the power booster.
Refer to Section 4C, Power Booster.
8. Install the instrument panel assembly. Refer to Section 9E, Instrument/Driver Information.

D24D007

DAEWOO M-150 BL2

HYDRAULIC BRAKES 4A 13

SPECIFICATIONS
GENERAL SPECIFICATIONS

0.8 SOHC Engine

Application

Millimeters

Inches

Brake Drums:
Inside Diameter
Maximum Rebore Diameter
Out-of-Round

180
182
0.04

7.09
7.17
0.0016

Brake Rotors:
Discard Thickness
Lateral Runout (Installed)
Rotor Diameter
Rotor Thickness (New)

10
0.05
236
12.7

0.4
0.002
9.3
0.5

Master Cylinder:
Bore Diameter

20.64

0.81

48

1.89

Wheel Cylinder Diameter:

17.46

0.69

Brake Pedal:
Free Play
Height
Stroke

6 10
200
30

0.24 0.31
7.87
1.18

Caliper:
Piston Diameter

Type

Brake Fluid

DOT3 or DOT4

Capacity

0.45 L (0.48 qt.)

FASTENER TIGHTENING SPECIFICATIONS

Application

NSm

Lb-Ft

Lb-In

16

12

25.5

19.1

18

13

Brake Pedal Bracket Mounting Bolts

18 26

13 20

Brake Pedal Bracket Mounting Nuts

18 26

13 20

Stoplamp Switch Mounting Bracket Bolts

9 12

80 106

Brake Pipe Fittings

Front Brake Hose-to-Caliper Bolt

Brake PedaltoPedal Bracket Hex Bolt

DAEWOO M-150 BL2

4A 14 HYDRAULIC BRAKES

SCHEMATIC AND ROUTING DIAGRAMS

BRAKE LAMP WARNING CIRCUIT

D17A201B

STOPLAMP SWITCH CIRCUIT

D17A202B

DAEWOO M-150 BL2